Method of forming self-supporting pleated filter media

ABSTRACT

The method of forming pleated filter media includes providing a generally planar web of filter material, folding the web to form a pleated web having a plurality of fold lines, arranging the plurality of pleats in a first spaced configuration defined by a first distance between adjacent pleat tips, applying a continuous strand of adhesive to the web, and adjusting the arrangement of the plurality of pleats into a second spaced configuration defined by a second distance between adjacent pleat tips. The web has a front face and a rear face. Each fold line is intermediate oppositely sloping first and second wall surfaces. The plurality of fold lines form a plurality of pleats having a first plurality of pleat tips and a second plurality of pleat valleys. The second distance is different from the first distance.

FIELD OF THE INVENTION

The present invention relates generally to making filter media and, moreparticularly, to a method of making a self-supporting pleated filtermedia.

BACKGROUND OF THE INVENTION

The surface area of filter media is a major factor in determining flowresistance (i.e., pressure drop) and loading capacity of a pleatedfilter. The surface area of a pleated filter media is determined by thesize of the pleated filter, the depth of the pleats, and the pleatdensity. Since the external dimensions of pleated filters are oftenrestricted by the particular application, the number of pleats per inch(pleat density) can be increased to an optimal level to improvefiltration performance.

The ability of air filter media to withstand operating pressures istypically dependent upon the pleat count, the pleat depth, the pressuredrop of the media, loading capacity of the media, filter frame strength,bonding strength of the media to the frame, and the stiffness of thefilter media. The filter media can become unsteady when air pressure isapplied to one side. In the event the pleats deform or collapse, aportion of the surface area can be reduced and the pressure drop acrossthe filter element will increase, further increasing the force appliedto the filter media. Further, if the tips or peaks of the pleats do notremain in a straight line but instead become wavy, this may cause wallsof the pleats to contact one another and to close off some of thesurface area of the media. The end result is an increase in pressuredrop and a reduction in dust holding capacity.

There is a need for an automated method of manufacturing a pleatedfilter that has good flow characteristics and exhibits sufficientstability so that the pleats do not collapse or deform when subjected tooperating pressure.

BRIEF SUMMARY OF THE INVENTION

The method of forming pleated filter media includes providing agenerally planar web of filter material, folding the web to form apleated web having a plurality of fold lines, arranging the plurality ofpleats in a first spaced configuration defined by a first distancebetween adjacent pleat tips, applying a continuous strand of adhesive tothe web, and adjusting the arrangement of the plurality of pleats into asecond spaced configuration defined by a second distance betweenadjacent pleat tips. The web has a front face and a rear face. Each foldline is intermediate oppositely sloping first and second wall surfaces.The plurality of fold lines form a plurality of pleats having a firstplurality of pleat tips and a second plurality of pleat valleys. Thesecond distance is different from the first distance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of one embodiment of a system forpreforming one embodiment of a method of the present invention.

FIG. 1 a is an enlarged, partial side elevation view of a firstembodiment of filter media, produced by the system of FIG. 1.

FIG. 1 b is an enlarged, partial side elevation view of a secondembodiment of self supporting pleated media 42, produced by the systemof FIG. 1.

FIG. 2 is a schematic illustration of a second embodiment of a systemfor preforming a second embodiment of a method of the present invention.

FIG. 2 a is an enlarged, partial side elevation view of a secondembodiment of filter media, produced by the system of FIG. 2.

FIG. 3 is a perspective view of a front face of one embodiment of filtermedia produced by the system of FIG. 1 or FIG. 2.

FIG. 4 is a schematic illustration of a one embodiment of a system forfurther processing the media produced by the system of FIG. 1 or FIG. 2.

FIG. 5 is a perspective view of a rear face of one embodiment of filtermedia produced by the system of FIG. 1 or FIG. 2.

FIG. 6 is a perspective view of one embodiment of filter media disposedwithin a frame.

While the above-identified drawing figures set forth several embodimentsof the invention, other embodiments are also contemplated, as noted inthe discussion. In all cases, this disclosure presents the invention byway of representation and not limitation. It should be understood thatnumerous other modifications and embodiments can be devised by thoseskilled in the art which fall within the scope and spirit of theprincipals of this invention. The figures may not be drawn to scale.Like reference numbers have been used throughout the figures to denotelike parts.

DETAILED DESCRIPTION

One embodiment of the present invention is directed to aself-supporting, pleated filter for air filtration, and method of makingthe same. The method of the present invention provides for assembly ofthe pleated filter by an automated process at a high rate ofmanufacturing. The pleated filter of the present invention can be usedwith or without a reinforcing frame structure. The present method andapparatus may utilize conventional filter media, electret media, or avariety of other media suitable for air filtration, such as for furnaceapplications.

FIG. 1 is a schematic illustration of one embodiment of system 10 forpreforming one embodiment of a method of the present invention. Filterweb or filter media 12 is typically provided on roll 14. Filter media 12may optionally be preheated at heating station 16 to facilitateprocessing. In one embodiment, heating station 16 is an infrared heater.

A length of filter media 12 is advanced through pleater 18, which in oneembodiment is a rotary-score pleater. In one embodiment, filter media 12is scored at regularly spaced intervals with a conventional scorer or alaser cutter, for example. The scored filter media 12 continues to pleatfolding or gathering station 20. Heaters 22 are optionally provided forheat-setting pleats 24. In one embodiment, heaters 22 are infraredheaters. In the illustrated embodiment, pleats 24 are allowed to hangfreely before being advanced to pleat spacing device 26. In anotherembodiment, pleats 24 are retained in an accumulator or trough (notshown) before being advanced to pleat spacing device 26.

Initial pleat formation and pleat spacing may be performed by a varietyof methods, such as disclosed in U.S. Pat. No. 4,798,575 (Siversson);U.S. Pat. No. 4,976,677 (Siversson); and U.S. Pat. No. 5,389,175 (Wenz).In one embodiment, pleats 24 are individualized before conveyance topleat spacing device 26 by a pleat holding device (not shown). In oneembodiment, such a pleat holding device includes a paddlewheel forlifting individual pleats and a flighted or toothed conveyor belt forholding the pleats and feeding them onto pleat spacing device 26.

Pleated filter media 28 is disposed in an initial pleat spacingconfiguration in first zone 30 of pleat spacing device 26. Pleatedfilter media 28 includes a plurality of pleat tips 34 and sloping sidesurfaces 35, which are generally perpendicular to the direction ofpleating 37. One or more continuous adhesive strands 32 are applied topleat tips 34 along front face 36 of pleated filter media 28. Adhesivestrand 32 may be applied to pleated filter media 28 in first zone 30 ofpleat spacing device 26 as shown, or earlier in system 10. For example,adhesive strand 32 may instead be applied to pleated filter media 28 asthe media is held by the pleat holding device discussed above. Referenceto front face 36 or a rear face is for purposes of description only anddoes not indicate a required orientation of the pleated filter media 28.

The application of adhesive strand 32 is accomplished by varioustechniques, including drizzling a continuous bead of molten adhesive 32onto pleats tips 34 from applicator 38. In one embodiment, adhesivestrand 32 is disposed substantially normal to a direction of a pleatfold line. Pleat spacing device 26 is preferably a variable pitch devicesuch as a variable flight or variable pitch screw on a rotating spindle.The pitch variation is preferably gradual and linear from a first end offirst zone 30 to a transition point in second zone 40, with a constantpitch at the second end of second zone 40; however, other variationconfigurations can also be used. After the application of adhesivestrand 32 to pleat tips 34, the spacing of pleats 24 is adjusted into asecond spaced configuration in second zone 40. In the illustratedembodiment, the pleat spacing is narrowed in second zone 40 compared tofirst zone 30. This compression of pleat 24 spacing causes thecompression of glue strand 32 between pleats 24. In one embodiment, gluestrand 32 hardens or cures after the compression in second zone 40. Inone embodiment, one or more additional adhesive strands may be used.Such adhesive strands may have the same properties and configuration, orthey may differ. An additional adhesive strand may be disposed on top ofa previously applied strand or elsewhere on the pleated filter media 28.

Pleat spacing in one embodiment is determined by a distance at the endof second zone 40 (in pleating direction 37) between adjacent pleat tips34 or the number of pleat tips for a certain length in pleatingdirection 37. Pleat spacing in the illustrated embodiment at the end ofsecond zone 40 is about 3 to about 6 pleats per 2.54 centimeters (cm)(1.0 inch). In one embodiment, pleat depth or pleat height, measured asa vertical distance between pleat tips 34 and pleat valleys 46, isgenerally between about 1.27 cm and about 15.2 cm (0.5 inch to 6.0inches) and is more preferably slightly less than about 2.54 cm (1.0inch), slightly less than about 5.08 cm (2.0 inches), or slightly lessthan about 10.16 cm (4.0 inches), so that pleated filter media 28 fitsinto a 1 inch nominal, a 2 inch nominal, or a 4 inch nominal filtertrack. In one embodiment, the pleat height is about 1.8 cm (0.7 inch).While pleat tips 34 and pleat valleys 46 are illustrated with sharpfolds, it is also contemplated that they may instead constitute morecurved configurations, leading to a sinusoidal shaped pleating of filtermedia 12.

The stiffness of filter media 12 is a factor in determining thesuitability of a particular filter media for use in the presentinvention. A Taber V-5 Stiffness Tester, Model 150-B, made by TeledyneTaber of North Tonawanda, N.Y., can be used to evaluate the stiffness ofthe filter media. The V-5 stiffness tester operates by bending aspecimen about 38.1 millimeters wide by about 38.1 millimeters long (1.5inches by 1.5 inches) to a prescribed angular of deflection andmeasuring the force, in stiffness units ranging from 0-10, used toobtain this deflection. In many heating, ventilating and airconditioning (HVAC) applications, the air pressure is generally about 50Pascal (Pa) to about 350 Pa (0.2 to 1.4 inch water column (w.c.)) andthe face velocity is approximately 91.5-152.4 meters per minute (m/min)(300-500 feet per minute (ft/min)). For HVAC filtration applications,the minimum stiffness value is preferably greater than about 1.2stiffness units, more preferably greater than about 1.5 stiffness unitsand even more preferably greater than about 2 stiffness units.

Filter media 12 may be paper; porous films of thermoplastic or thermosetmaterials; nonwoven, such as melt blown or spunbond, webs of syntheticor natural fibers; scrims; woven or knitted materials; foams; electretor electrostatically charged materials; fiberglass media; or laminatesor composites of two or more materials. A nonwoven polymeric web ofpolyolefin, polyethylene or polypropylene is suitable, for example.Filter media 12 may also include sorbents, catalysts, and/or activatedcarbon (granules, fibers, fabric, and molded shapes). Electret filterwebs can be formed of the split fibrillated charged fibers as describedin U.S. Pat. No. RE 30,782. These charged fibers can be formed into anonwoven web by conventional means and optionally joined to a supportingscrim such as disclosed in U.S. Pat. No. 5,230,800 forming an outersupport layer. Alternatively, filter media 12 can be a melt blownmicrofiber nonwoven web, such as disclosed in U.S. Pat. No. 4,813,948which can be joined to a support layer during web formation as disclosedin that patent, or subsequently joined to a support web in anyconventional manner.

A particularly suitable media is a corona-treated spunbondpolyethylene/polypropylene twinned fiber, commercially available fromKimberly Clark Corporation under the designation Accuair. This media hasa basis weight of about 71 grams per square meter (g/m²) and a filamentdiameter of about 20 micrometers. Another suitable media is a blownpolypropylene microfiber having a basis weight of about 10 g/m² to about80 g/m² and an average filament diameter of about 2 micrometers to about17 micrometers. For a commercial air purifier application example,filter media 12 is preferably a blown polypropylene microfiber having abasis weight of about 20 g/m² to about 40 g/m² and an average filamentdiameter of about 2 micrometers. For an example commercial HVAC filterof 51 mm (2 inch) nominal frame depth and 61 cm (2 feet) by 61 cm (2feet) size, filter media 12 is preferably a blown polypropylenemicrofiber having a basis weight of about 30 g/m² and an averagefilament diameter of about 5 micrometers to about 7 micrometers. In oneembodiment, filter media 12 is between about 0.5 millimeter (mm) andabout 1.0 mm thick and is about 0.8 mm thick in a preferred example. Thepresent invention is particularly suitable for use with nonwovenpolymeric media, which are typically softer than fiberglass media, forexample. Adhesive strand 32 helps to retain pleat sharpness and spacingin these softer materials.

Laminated media can also be used as filter media 12. Such media mayconsist of laminated layers of the media discussed above or of othersubstrates laminated to one or more layers of filter media, for example.Such lamination can be accomplished by conventional hot melt laminationmethods using about 3 g/m² to about 6 g/m² of a hot melt adhesive suchas a polypropylene based hot melt adhesive. A suitable machine forachieving such lamination is available from ITW Dynatec, Hendersonville,Tenn. The adhesive is preferably applied in a discontinuous pattern tominimize blockage of the surface of filter media 12. In one embodiment,a pre-filter layer with a basis weight of about 60 g/m² to about 90 g/m²is used on the upstream side of filter media 12. Such a pre-filter layerconsists of polypropylene, polyethylene, polyethylene terephthalate, orblends of these materials, in one example. In one embodiment, anadditional scrim layer may be used to offer added protection to thedownstream side of filter media 12. Such a scrim layer typically has abasis weight of about 10 g/m² to about 15 g/m² and consists of nonwovenpolypropylene, polyethylene, polyester based polymers, or blends ofthese materials, in one example.

Adhesive strand 32 may be composed of a wide range of suitable adhesiveswhich bond to filter media 12 and offer structural support to the media.In some embodiments, hot-melt and foamed hot-melt adhesives arepreferred because they can easily be applied to pleat tips 34 in amolten state and then cured, hardened, or cross-linked after the pleatspacing is changed, thereby acting as spacers to maintain the finalpleat spacing. A particularly suitable hot melt adhesive is an adhesivehaving between about 5% and about 10% paraffin wax and between about 10%and about 30% polyethylene wax. In one embodiment, the adhesive has aviscosity of about 5,600 centipoise (cP) at 121.1° C. (250° F.). Anothersuitable adhesive is available from 3M Company under product number3748; it has a viscosity of about 5,000 cP (Brookfield ThermoselViscometer in Centipoise) at 190.6° C. (375° F.). Yet another suitableadhesive is an ethyl vinyl acetate based hot melt adhesive with aviscosity of about 10,500 cP at 148.9° C. (300° F.). In one embodiment,a suitable adhesive has a set rate of less than about 3 minutes for a3.18 mm (⅛ inch) diameter bead and preferably has a set rate of lessthan about 45 seconds.

In one embodiment, applicator 38 is part of a Nordson Grid Melter systemwith a tank temperature between about 110° C. (230° F.) and 125° C.(257° F.) and preferably at about 120° C. (248° F.). The hose and headtemperatures are preferably between about 99° C. (210° F.) and 177° C.(350° F.); more preferably between about 102° C. (216° F.) and 106° C.(223° F.); and most preferably at about 104° C. (219° F.). Applicator 38has a nozzle with an orifice size between about 1.14 mm (0.045 inch) andabout 1.91 mm (0.075 inch) and preferably at about 1.52 mm (0.060 inch).The orifice of applicator 38 is positioned between about 0.5 mm (0.02inch) and about 4.0 mm (0.16 inch) and preferably at about 2.0 mm (0.08inch) above pleat tips 34.

In one embodiment, a pleat height is about 18 mm (0.71 inch). Applicator38 applies adhesive strand 32 to pleat tips 34 at an initial spacing infirst zone 30 of between about 7.2 mm (0.28 inch) and about 23.4 mm(0.92 inch) between adjacent pleat tips 34; more preferably, the initialspacing is between about 10.8 mm (0.43 inch) and about 18.0 mm (0.71inch). Because adhesive strand 32 is molten and applied toalready-formed pleats 24, the adhesive causes essentially no resistanceto pleat formation. In one embodiment, in first zone 30, a ratio betweenpleat spacing and pleat height is between about 0.4 and about 1.3, witha preferred ratio between about 0.6 and 1.0. These ratios can be used todetermine suitable pleat spacings for other pleat heights. In oneembodiment, adhesive strand 32 is applied as a continuous adhesivestrand. This allows for ease of application, the use of simpler controlmodules, increased reliability and lower cost.

After application of adhesive strand 32, pleats 24 are compressed insecond zone 40 to a second spacing of between about 1.8 mm (0.07 inch)and about 12.6 mm (0.50 inch) between adjacent pleat tips 34; morepreferably, the second spacing is between about 2.7 mm (0.11 inch) andabout 9 mm (0.35 inch); even more preferably, the second spacing isbetween about 4 mm (0.16 inch) and about 7 mm (0.28 inch). In oneembodiment, in second zone 40, a ratio between pleat spacing and pleatheight is between about 0.10 and about 0.70, with a preferred ratiobetween about 0.15 and 0.50. It is contemplated that variations to thedescribed materials and conditions can be used to achieve pleated mediawith other appearances, bridging effects, and pleat pack stabilizationeffects.

The combination of pleated filter media 28 and adhesive strands 32 formself-supporting pleated media 42. In one embodiment, self-supportingpleated media 42 is cut to a desired length by cutting station 44.

FIG. 1 a is an enlarged, partial side elevation view of one embodimentof self-supporting pleated media 42, produced by the system of FIG. 1. Aplurality of fold lines in self-supporting pleated media 42 alternatelyconstitute pleat tips 34 and pleat valleys 46. Each fold line isintermediate oppositely sloping wall surfaces 35. Compression ofadhesive strand 32 and gravity cause the adhesive to travel downward onsloping walls 35 toward an inside surface of valley 46 so that strand 32is substantially nonlinear in the viewed side elevation dimension.Adhesive strand 32 thereby lends rigidity, structural integrity anddimensional stability to each pleat 24 so that self-supporting pleatedmedia 42 is better suited to machine handling in subsequent processingand maintains its original form during use. Adhesive strand 32 maintainspleat spacing and prevents pleat collapse.

In a preferred embodiment, adhesive strand 32 does not reach an insidesurface of valley 46 and is thereby in discontinuous contact with filtermedia 12. Therefore, the shape of pleat 24 is not deformed by an excessof adhesive 32, adhesive 32 blocks less surface area of filter media 12,and cost savings are achieved by using less adhesive 32. The stiffnessof filter media 12, the setting properties of adhesive 32, and settingsof system 10 are preferably chosen so that hardened or cured adhesive 32maintains the shape of pleats 24 in second zone 40 of pleat spacingdevice 26 without causing pleat shape deformation.

FIG. 1 b is an enlarged, partial side elevation view of a secondembodiment of self-supporting pleated media 42, produced by the systemof FIG. 1. In the illustrated embodiment, adhesive 32 and processingconditions are selected so that adhesive strand 32 travels furtherdownward on sloping walls 35 toward an inside surface of valley 46. Forexample, an adhesive with lower viscosity or a longer set rate may beselected, the temperature at nozzle 38 may be higher, a wider initialpleat spacing in first zone 30 may be used, or the line speed of system10 may be decreased. In the illustrated embodiment, adhesive strand 32bonds to pleat tips 34 and a major portion of sloping walls 35. Adhesivestrand 32 thereby lends rigidity, structural integrity and dimensionalstability to each pleat 24 so that self-supporting pleated media 42 isbetter suited to machine handling in subsequent processing and maintainsits original form during use. Adhesive strand 32 maintains pleat spacingand prevents pleat collapse.

In a preferred embodiment, adhesive strand 32 does not reach an insidesurface of valley 46 and is thereby in discontinuous contact with filtermedia 12; therefore, the shape of pleat 24 is not deformed by an excessof adhesive 32. In another embodiment, adhesive strand 32 does reach aninside surface of valley 46 so that strand 32 is in continuous contactwith filter media 12. In the illustrated embodiment, a portion ofadhesive strand 32 on a first wall surface 39 contacts a portion ofadhesive strand 32 on a second wall surface 41 to form a finger thatacts as a spacer and structural reinforcer for pleats 24. In oneembodiment, these portions of adhesive strand 32 cure together. Inanother embodiment, the sections of adhesive strand 32 may partiallycure individually before coming into contact, thereby forming a knitline at the interface between the two sections. The depth of travel ofadhesive strand 32 toward an inside surface of valley 46 is determinedby a number of factors, including, for example, the adhesive settingproperties, the amount of adhesive used relative to the pleat spacing,the temperature at nozzle 38, the width of initial pleat spacing infirst zone 30, the line speed of system 10 in direction of pleating 37,and air temperature and flow rate. The stiffness of filter media 12, thesetting properties of adhesive 32, and settings of system 10 arepreferably chosen so that hardened or cured adhesive 32 maintains theshape of pleats 24 in second zone 40 of pleat spacing device 26 withoutcausing pleat shape deformation.

FIG. 2 is a schematic illustration of a second embodiment of system 10for preforming a second embodiment of a method of the present invention.The steps for forming pleats 24 described relative to FIG. 1 are thesame as those used relative to this second embodiment. After theapplication of adhesive strand 32 to pleat tips 34 in first zone 30, thespacing of pleats 24 is widened in second zone 40 compared to first zone30. This widening of pleat 24 spacing causes a drawing or bridging ofpartially cooled or hardened adhesive strand 32 between pleats 24. Thisis possible because the adhesive has greater strength in a partiallycooled state as compared to the molten state. In one embodiment,adhesive strand 32 hardens or cures completely after the widening insecond zone 40, thereby forming a pleat spacer. Adhesive 32 andprocessing conditions are selected to achieve the bridging effect. Forexample, an adhesive with higher viscosity or a faster set rate may beselected or the temperature at nozzle 38 may be lower, for example.Additional adhesive strands can be used if additional beam strength isrequired. These additional strands can be applied concurrently withstrand 32 or after strand 32 has cooled. In one embodiment, anadditional adhesive strand is applied on top of strand 32 in or aftersecond zone 40. In one embodiment, one or more other adhesive strandsmay be used. Such adhesive strands may have the same properties andconfiguration, or they may differ. An additional adhesive strand may bedisposed on top of a previously applied strand or elsewhere on thepleated filter media 28.

In one embodiment, a pleat height is about 18 mm (0.71 inch). Applicator38 applies adhesive strand 32 to pleat tips 34 at an initial spacing infirst zone 30 of between about 1.8 mm (0.07 inch) and about 7.2 mm (0.28inch) between adjacent pleat tips 34; more preferably, the initialspacing is between about 3.6 mm (0.14 inch) and about 5.4 mm (0.21inch). In one embodiment, in first zone 30, a ratio between pleatspacing and pleat height is between about 0.1 and about 0.4, with apreferred ratio between about 0.2 and about 0.3. These ratios can beused to determine suitable pleat spacings for other pleat heights. Inone embodiment, adhesive strand 32 is applied as a continuous adhesivestrand. This allows for ease of application, the use of simpler controlmodules, increased reliability and lower cost. After application ofadhesive strand 32, pleats 24 are widened in second zone 40 to a secondspacing of between about 3.6 mm (0.14 inch) and about 27.0 mm (1.06inch) between adjacent pleat tips 34; more preferably, the secondspacing is between about 5.4 mm (0.21 inch) and about 18.0 mm (0.71inch). In one embodiment, in second zone 40, a ratio between pleatspacing and pleat height is between about 0.2 and about 1.5, with apreferred ratio between about 0.3 and about 1.0. It is contemplated thatvariations to the described materials and conditions can be used toachieve pleated media with other appearances, bridging effects, andpleat pack stabilization effects.

FIG. 2 a is an enlarged, partial side elevation view of a secondembodiment of self-supporting pleated media 42, produced by the systemof FIG. 2. Bridging of adhesive strand 32 causes the adhesive to stretchbetween adjacent pleat tips 34. After such stretching, adhesive strand32 hardens or cures, thereby maintaining the widened pleat spacing ofself-supporting pleated media 42. Because the final pleat spacing is notdependent solely on the thickness of adhesive strand 32, the illustratedembodiment accomplishes this objective with minimal adhesive use andtherefore with minimal air flow restriction due to the presence ofadhesive strand 32 blocking portions of sloping side surfaces 35 offilter media 12. The stiffness of filter media 12, the settingproperties of adhesive 32, and settings of system 10 are preferablychosen so that hardened or cured adhesive 32 maintains the shape ofpleats 24 in second zone 40 of pleat spacing device 26 without causingpleat shape deformation. For example, if particularly soft filter media12 are used, the settings and materials of system 10 can be selected sothat adhesive strand 32 extends more deeply down pleat walls 35, therebylending greater strength to self-supporting pleated media 42. Asillustrated by FIGS. 1 a and 2 a, system 10 of the present invention canbe used to produce self-supporting pleated media 42 with both very closepleat spacings and very wide pleat spacings.

FIG. 3 is a perspective view of front face 36 of one embodiment ofself-supporting pleated media 42 produced by system 10 of FIG. 1 or FIG.2. In one embodiment of system 10, a plurality of applicators 38dispense a plurality of parallel adhesive strands 32 ontoself-supporting pleated media 42; in one embodiment, strands 32 arepositioned at regular intervals. In one embodiment, adjacent adhesivestrands 32 are placed between about 2.5 cm (1 inch) to about 15.2 cm (6inches) apart and are more preferably placed between about 5.1 cm (2inches) to about 10.2 cm (4 inches) apart. Adhesive strands 32 providedimensional stability to pleats 24 of pleated filter media 28. Thus,self-supporting pleated media 42 can be used in filtration applications,with or without a frame structure, or as an insert into a permanent orreusable frame. Pleated filter media 28 and adhesive strands 32 form aself-supporting pleated media 42 that can be cut, machined handled orotherwise processed. In embodiments where the self-supporting pleatedmedia 42 is used without frame members, the self-supporting pleatedmedia 42 exits system 10 after the cutting station 44. Self-supportingpleated media 42 is preferably sufficiently strong so that pleats 24 donot collapse or bow excessively when subjected to the air pressuretypically encountered in forced air ventilation systems.

The cut self-supporting pleated media 42 section has opposite end edges52 and opposite side edges 54. For HVAC applications, the length andwidth of cut self-supporting pleated media 42 is typically from about30.5 centimeters wide by about 30.5 centimeters long (12 inches by 12inches); to about 61.0 centimeters wide by about 61.0 centimeters long(24 inches by 24 inches); to about 50.8 centimeters wide by about 76.2centimeters long (20 inches by 30 inches). Self-supporting pleated media42 is usually cut into square or rectangular shapes, though other sizesand configurations are possible.

FIG. 4 is a schematic illustration of a one embodiment of system 50 forfurther processing self-supporting pleated media 42 produced by system10 of FIG. 1 or FIG. 2. Self-supporting pleated media 42 can be usedwithout a frame or inserted into a permanent frame that permitsself-supporting pleated media 42 to be easily changed. Alternatively,reinforcing or frame members are optionally applied for some filtrationapplications. The step of applying the frame members typically includespositioning a portion of the frame members onto a portion of the frontface and the rear face of the filter media. An adhesive is typicallyapplied between the perimeter of the filter media and the frame members.The method may be performed using a fully automated system. A suitablesystem and method are disclosed in U.S. patent application Pub. No.2003/0172633 (Duffy).

In the illustrated system 50, self-supporting pleated media 42 isflipped from the orientation shown with respect to system 10, so thatrear face 48 faces upward. In one embodiment, a continuous strip offrame material 56 from roll 58 is applied to opposite sides 54 (shown inFIG. 3) of the self-supporting pleated media 42 section parallel to thedirection of pleating 37. Frame material 56 is typically composed ofpaper products, such as chipboard, or polymeric or metallic materials.An adhesive, such as a hot melt adhesive, is applied to a first flangeof a U-shaped channel formed from the frame material 56 at nozzle 60.Nozzle 60 can apply single or multiple adhesive beads or coatings to theflanges, fold lines, and/or main body of frame material 56, or anycombination thereof, prior to application and bonding of frame material56 to pleats 24 to form a U-shaped channel frame. While the use ofnozzles is described, other applicators may also be used, such as beltor roller systems.

In one embodiment, an additional adhesive for sealing the side ends ofpleats 24 is applied by side glue applicator 62 to form substantiallylinear side band glue strip 64. In an unillustrated embodiment, sideband glue strip 64 can also extend the entire height of pleats 24 orbeyond. In one embodiment, an additional adhesive for reinforcing theself-supporting pleated media 42 on rear face 48 is applied by tip glueapplicator 66 to form substantially linear tip glue strip 68. Side bandglue strip 64 and tip glue strip 68 are formed from any suitableadhesive using conventional materials and methods known in the art. Inone embodiment, each of side glue applicator 62 and tip glue applicator66 are transfer bands or belts. An adhesive for forming either side bandglue strip 64 or tip glue strip 68 is applied to a band made of amaterial such as metal or silicone rubber. The adhesive at leastpartially cools on the band. Then, the cooled adhesive is transferredonto self-supporting pleated media 42 and pressed thereon to adhere theside band glue strip 64 or tip glue strip 68 onto self-supportingpleated media 42. Unlike adhesive strands 32, side band glue strip 64and tip glue strip 68 are applied to self-supporting pleated media 42after the spacing of pleats 24 has been set. Moreover, the adhesive forside band glue strip 64 and tip glue strip 68 are not applied directlyto filter media 12, but are first applied to a transfer mechanism andthen transferred onto filter media 12. Also, side band glue strip 64 andtip glue strip 68 are preferably formed of relatively high viscosityadhesives or substantially set adhesives that remain in a linearconfiguration as applied and exhibit minimal conformation to the shapeof filter media 12.

Other reinforcing members and techniques can also be used, as disclosedin U.S. Pat. No. 6,521,011 (Sundet et al.). Moreover, reinforcingmembers may be positioned in any orientation relative to self-supportingpleated media 42. For example a net or scrim material may be applied tofront face 36 of pleated filter media 28 after the application ofadhesive strand 32. Such a scrim would readily bond to the adhesive ontop of pleat tips 34.

In one embodiment, after the application of suitable reinforcementmembers, a hot melt adhesive is applied to the second flange of theU-shaped channel of frame material 56 at nozzle 70 (shown schematicallyonly; the actual orientation may vary in practice). Frame material 56 isbent into its U-shaped configuration at frame bending station 72 so thatthe ends of the U-shaped channel extend partially onto the front face 36and rear face 48 of the self-supporting pleated media 42 (see FIG. 6).

The U-shaped channel of the side frame members serve to furtherstabilize the self-supporting pleated media 42 and to seal the ends ofpleats 24 to prevent air bypass in the final pleated filter. In oneembodiment, a viscous adhesive such as a foamed adhesive, a filledadhesive or a caulk is used to seal the ends of pleats 24 to the framemembers. Latex caulk is well suitable for this purpose since it is lowcost and has low volatile organic content. On the other hand, latexcaulks have a long set time. Therefore, other adhesives, such as hotmelt adhesives, are utilized in one embodiment to bond the two sides ofthe U-shaped channel formed from the frame material 56 to the pleat tips34. A variety of techniques may be used for applying the frame membersto self-supporting pleated media 42, such as disclosed in U.S. Pat. No.4,731,047 (Lobb) and U.S. Pat. No. 6,406,509 (Duffy).

The self-supporting pleated media 42 and side frame members are rotated90 degrees at rotation station 74 to permit application of the end framemembers at a framing station 76. Alternatively, the frame members can beconfigured as two box structures that are positioned over the front andrear faces 36, 48, respectively, of the self-supporting pleated media42, with overlapped circumferential portions, such as disclosed in U.S.Pat. No. 5,782,944 (Justice). In another embodiment, the frame memberscan be configured as a one-sided die-cut frame that is folded around theself-supporting pleated media 42.

An assembly including the web of self-supporting pleated media 42 andattached frame material 56 is cut at cutting station 78 to desiredlengths. Alternatively, self-supporting pleated media 42 withreinforcing side band glue strips 64 and reinforcing tip glue strips 68can be cut to size before application of frame material 56.

Rather than using the illustrated system 50, rear face 48 may be leftuntreated, or other treatments can alternatively be used for rear face48. For example, rather than using reinforcing strips of adhesive 64,68, reinforcing strips or members may be constructed from variousplastic, paper or chipboard products; polymeric materials; or metals. Inorder to minimize pressure drop across the self-supporting pleated media42, the reinforcing materials can be configured as strips, films,scrims, meshes, nets, strands, filaments, or other porous structuressuch as perforated sheets, for example. In one embodiment, thereinforcing structure includes one or more reinforcing members extendingin the direction of pleating generally along the contour of the pleattips and sloping side surfaces of the rear face. In one embodiment, thereinforcing members are bonded to pleat tips 34 of the filter media 12.

FIG. 5 is a perspective view of rear face 48 of one embodiment ofself-supporting pleated media 42 produced by a variation of system 50.In the illustrated embodiment, self-supporting pleated media 42 has notbeen framed, but has been processed to include side band glue strips 64and tip glue strips 68.

FIG. 6 is a perspective view of one embodiment of pleated filter 90,including self-supporting pleated media 42 disposed within frame 80.Frame 80 consists of U-shaped side frame channel members 82 and U-shapedend frame channel members 84. In one embodiment, each frame channelmember 82, 84 covers an edge 54, 52 (see FIG. 5) and at least a portionof front face 36 and rear face 48. In the illustrated embodiment, aplanar reinforcing member in the form of metal mesh scrim 86 is disposedextending substantially across the entire rear face 48. Scrim 86 isbonded to pleat tips 34 to provide dimensional stability to pleatedfilter 90.

In one embodiment, scrim 86 is a galvanized steel expanded wire meshlaminated to pleat tips 34 with a hot melt adhesive. The wire mesh isabout 0.25 mm (0.010 inch) thick, the diamond-shaped openings are about25.4 mm (1.0 inch) by about 19.1 mm (0.75 inch), and the strands areabout 0.30 mm (0.012) inch wide. A suitable wire mesh is available fromWallner Tooling/Expac, Inc. The wire mesh is coated with hot-meltadhesive using a conventional roll coater where the application roll ispartially submerged in the melted hot melt adhesive. As the rollrotates, it picks up a coating of hot melt adhesive, which istransferred to the expanded wire as the wire comes into contact with theroll. While the adhesive is still semi-molten, the wire is placed intocontact with pleat tips 34, making bonds where the coated wire contactspleat tips 34. Because of the high number of bonding points, scrim 86aids in maintaining proper pleat spacing and preventing buckling orcollapse of pleats 24. Use of scrim 86 may be used in combination with,or in place of, any of the reinforcing members discussed herein. Forexample, with reference to FIG. 4, an applicator may be used to applyadhesive for adhering scrim 86 rather than for applying tip glue strip68. Moreover, a scrim may be applied to front face 36 as well as or inplace of a scrim applied to rear face 48.

One embodiment of pleated filter 90 constructed according to the abovedisclosure was tested according to ASHRAE 52.2. The initial pressuredrop was about 0.18 inch w.c. and the E1, E2 and E3 minimum compositeefficiencies were about 61%, about 88% and about 97%, respectively.Pleated filter 90 possessed sufficient support to allow loading to about1.0 inch w.c.

The complete disclosures of all patents, patent applications, andpublications are incorporated herein by reference as if individuallyincorporated. Although the present invention has been described withreference to preferred embodiments, workers skilled in the art willrecognize that changes may be made in form and detail without departingfrom the spirit and scope of the invention, and it should be understoodthat this invention is not to be unduly limited to the illustrativeembodiments set forth herein. For example, the teachings herein may becombined with conventional methods and articles to form new combinationsof features.

1. A method of forming pleated filter media comprising: providing agenerally planar web of filter material, the web having a front face anda rear face; folding the web to form a pleated web having a plurality offold lines, each fold line being intermediate oppositely sloping firstand second wall surfaces, wherein the plurality of fold lines form aplurality of pleats having a first plurality of pleat tips and a secondplurality of pleat valleys; arranging the plurality of pleats in a firstspaced configuration defined by a first distance between adjacent pleattips; applying a continuous strand of adhesive to the web; and adjustingthe arrangement of the plurality of pleats into a second spacedconfiguration defined by a second distance between adjacent pleat tips,the second distance being different from the first distance.
 2. Themethod of claim 1 wherein the filter material comprises a laminatematerial.
 3. The method of claim 1 wherein the filter material is anonwoven polymeric material.
 4. The method of claim 3 wherein thenonwoven polymeric material comprises an electret material.
 5. Themethod of claim 1 wherein the adhesive contacts the web at a pleat tip;contacts the web at a portion of a wall surface; and does not contactthe web in a valley.
 6. The method of claim 1 wherein the adhesivecontacts the web along a majority of a length of each wall surface. 7.The method of claim 1 wherein the second distance is between about 1.8mm and about 12.6 mm.
 8. The method of claim 1 wherein the seconddistance is between about 3.6 mm and about 27.0 mm.
 9. The method ofclaim 1 wherein a ratio between the second distance and pleat height andis between about 0.1 and about 0.7.
 10. The method of claim 1 wherein aratio between the second distance and pleat height and is between about0.2 and about 1.5.
 11. The method of claim 1 wherein a portion ofadhesive on a first wall surface contacts a portion of adhesive on asecond wall surface.
 12. The method of claim 1, further comprisingapplying a plurality of continuous strands of adhesive to the web. 13.The method of claim 12, wherein the plurality of strands are positionedparallel to, and spaced apart from, each other.
 14. The method of claim13, wherein a strand is spaced from an adjacent strand by between about2.5 cm and about 12.7 cm.
 15. The method of claim 1 wherein the webfurther comprises a side edge, the side edge being normal to a directionof the fold line, the method further comprising: applying a side bandreinforcement strip on the side edge.
 16. The method of claim 1 furthercomprising: applying a tip band reinforcement strip on the pleatvalleys.
 17. The method of claim 1 wherein the web further comprises apair of opposite side edges and a pair of opposite end edges, the methodfurther comprising: applying a frame member at each edge.
 18. The methodof claim 17 further comprising: covering an edge and at least a portionof each of the front face and the rear face with each frame member. 19.The method of claim 1 further comprising: applying a reinforcing memberto the rear face of the web.
 20. The method of claim 19 wherein thereinforcing member is substantially planar.
 21. The method of claim 20wherein the step of applying the substantially planar reinforcing memberincludes adhering the reinforcing member to the rear face of the web.22. The method of claim 21 wherein the planar reinforcing member is ametal mesh scrim.
 23. The method of claim 1 wherein the adhesive is ahot-melt adhesive.
 24. The method of claim 23 wherein the adhesive is ina molten state during the application step and transforms into a solidstate after the adjusting step.
 25. The method of claim 1 furthercomprising: scoring the web at regularly spaced intervals before foldingthe web.
 26. The method of claim 1 further comprising: heat setting theplurality of pleats.
 27. The method of claim 1 wherein the seconddistance is less than the first distance.
 28. The method of claim 1wherein the second distance is greater than the first distance.
 29. Amethod of forming pleated filter media comprising: providing a generallyplanar web of nonwoven polymeric material, the web having a front faceand a rear face, wherein the web further comprises a pair of oppositeside edges and a pair of opposite end edges; scoring the web atregularly spaced intervals; folding the web to form a pleated web havinga plurality of fold lines, each fold line being intermediate oppositelysloping first and second wall surfaces, wherein the plurality of foldlines form a plurality of pleats-having a first plurality of pleat tipsand a second plurality of pleat valleys; heat setting the plurality ofpleats; arranging the plurality of pleats in a first spacedconfiguration defined by a first distance between adjacent pleat tips;applying a plurality of parallel, continuous strands of adhesive to theweb so that each strand of adhesive contacts the web at a pleat tip,contacts the web at a portion of a wall surface, and does not contactthe web in a valley, wherein a strand is spaced from an adjacent strandby between about 2.5 cm and about 12.7 cm; adjusting the arrangement ofthe plurality of pleats into a second spaced configuration defined by asecond distance between adjacent pleat tips, the second distance beingdifferent from the first distance, wherein the second distance isbetween about 1.8 mm and about 12.6 mm; adhering a metal mesh scrim tothe rear face of the web; and applying a frame member at each edge,wherein each frame member covers an edge and at least a portion of eachof the front face and the rear face.
 30. The method of claim 1 whereinarranging the plurality of pleats, applying a continuous strand ofadhesive, and adjusting the arrangement of the plurality of pleatsoccurs in-line.
 31. The method of claim 1 wherein the step of adjustingthe arrangement of the plurality of pleats is characterized by theadhesive being molten.